Polyoxymethylene polymer composition having low friction

ABSTRACT

A tribologically modified polyoxymethylene polymer composition is disclosed. The polyoxymethylene polymer composition is comprised of a polyoxymethylene polymer, reinforcing fibers, and at least one tribological modifier. The tribological modifier may comprise at least one tribological modifier comprising an ultra-high molecular weight silicone having a kinematic viscosity of greater than about 100,000 mm 2 s −1 . The composition may exhibit a dynamic coefficient of friction against a counter-material of from about 0.001 to about 0.2. The polyoxymethylene polymer compositions provide polymer articles with improved tribological properties and mechanical properties. In one embodiment, the composition contains a polyoxymethylene polymer having functional groups, a coupling agent, reinforcing fibers, and the above silicone.

RELATED APPLICATIONS

The present application is based on and claims priority to U.S. Provisional Patent application Ser. No. 62/093,240, filed on Dec. 17, 2014, which is incorporated herein by reference.

BACKGROUND

Polyacetal polymers, which are commonly referred to as polyoxymethylene polymers, have become established as exceptionally useful engineering materials in a variety of applications. For instance, because polyoxymethylene polymers have excellent mechanical properties, fatigue resistance, abrasion resistance, chemical resistance, and moldability, they are widely used in constructing polymer articles, such as articles for use in the automotive industry and the electrical industry.

The mechanical properties of polyoxymethylene molding compositions are the reason for theft use in numerous applications. To improve their properties, polyoxymethylene polymers are often provided with additives to adapt the properties for a specific application, for example by using reinforcing fibers or tribological modifiers. For instance, polyoxymethylene polymers have been combined with a tribological modifier for producing polymer compositions well suited for use in tribological applications where the polymer article is in moving contact with other articles, such as metal articles, plastic articles, and the like. These tribological applications can include embodiments where the polymer composition is formed into gear wheels, pulleys, sliding elements, and the like. The addition of a tribological modifier can provide a composition with a reduced coefficient of friction, little frictional noise, and low wear.

In the past, high molecular weight polyolefins have been used to improve the wear resistance of polyoxymethylene resins. For instance, U.S. Pat. No. 5,482,987, which is incorporated herein by reference in its entirety, discloses a self-lubricating, low wear composition containing a polyoxymethylene and a lubricating system comprising a high molecular weight polyethylene, a high density polyethylene, and other components. U.S. Pat. No. 5,641,824, which is incorporated herein by reference in its entirety, discloses a self-lubricating melt blend of a polyoxymethylene and an ultra-high molecular weight polyethylene. However, polyoxymethylene compositions modified with these high molecular weight polyethylenes may have a less than desirable surface appearance as well as defects that may detract from the wear properties of the compositions and articles produced therefrom.

Although polyoxymethylene has been tribologically modified in the past, further improvements are still necessary. For instance, a need exists for providing a polyoxymethylene polymer composition and a polymer article produced therefrom with improved tribological properties. In particular, a need exists for providing a polyoxymethylene polymer composition and a polymer article produced therefrom with a reduced coefficient of friction when in contact with other moving articles and improved wear properties.

SUMMARY

According to one embodiment, the present disclosure is directed to a polymer composition. The composition is comprised of a polyoxymethylene copolymer and at least one tribological modifier comprising an ultra-high molecular weight silicone having a kinematic viscosity of greater than about 100,000 mm²s⁻¹.

For example, in one embodiment, the polymer composition contains a polyoxymethylene polymer. The polyoxymethylene polymer can have reactive groups at terminal positions on the polymer. For example, the reactive groups may comprise hydroxy groups. In addition to the polyoxymethylene polymer, the polymer composition may contain reinforcing fibers and a coupling agent. The reinforcing fibers may be present in the polymer composition in an amount from about 5% to about 55% by weight. The coupling agent may be configured to couple the polyoxymethylene polymer to the reinforcing fibers. The composition can further contain at least one tribological modifier that comprises an ultra-high molecular weight silicone. The ultra-high molecular weight silicone may be present in the polymer composition in an amount from about 0.1% to about 10% by weight, such as from about 0.5% to about 7% by weight, such as from about 0.5% to about 4% by weight. The silicone may comprise a polydimethylsiloxane.

In one embodiment, the composition may contain a second tribological modifier.

Other features and aspects of the present disclosure are discussed in greater detail below.

DETAILED DESCRIPTION

Reference now will be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations.

In general, the present disclosure is directed to a polyoxymethylene polymer composition and to polymer articles made from the composition. The polymer composition contains a polyoxymethylene polymer and has improved tribological properties such as a reduced coefficient of friction. The tribological properties can be improved by utilizing tribological modifiers. In general, the polyoxymethylene polymer composition comprises a polyoxymethylene polymer and at least one tribological modifier. For instance, the tribological modifier may comprise an ultra-high molecular weight silicone.

The present inventors have discovered that by utilizing the polyoxymethylene composition of the present invention, improved sliding properties and a reduced coefficient of friction against other surfaces may be obtained. In particular, the composition and a polymer article made from the composition may exhibit a reduced coefficient of friction against other surfaces or counter-materials while still exhibiting desirable mechanical properties. In addition, these compositions and articles also generate little frictional noise and experience low wear.

In one particular embodiment, the polymer composition of the present disclosure includes a polyoxymethylene polymer that contains reactive or functional groups at terminal positions on the polymer chain. The polyoxymethylene polymer is combined with reinforcing fibers and a coupling agent. The coupling agent couples the reinforcing fibers to the polymer matrix. The improved adhesion between the fibers and the polymer matrix results in a composition having improved mechanical properties, including tribological properties. In order to further improve the tribological properties of the polymer composition, the composition can then contain a tribological modifier, such as an ultra-high molecular weight silicone. The above combination of components has been found to lead to dramatically improved wear performance particularly at slow sliding speeds.

Polyoxymethylene Polymer

According to the present disclosure, the polyoxymethylene polymer composition comprises a polyoxymethylene polymer.

The preparation of the polyoxymethylene polymer can be carried out by polymerization of polyoxymethylene-forming monomers, such as trioxane or a mixture of trioxane and a cyclic acetal such as dioxolane in the presence of a molecular weight regulator, such as a glycol. The polyoxymethylene polymer used in the polymer composition may comprise a homopolymer or a copolymer. According to one embodiment, the polyoxymethylene is a homo- or copolymer which comprises at least 50 mol. %, such as at least 75 mol. %, such as at least 90 mol. % and such as even at least 97 mol. % of CH₂O-repeat units.

In one embodiment, a polyoxymethylene copolymer is used. The copolymer can contain from about 0.1 mol. % to about 20 mol. % and in particular from about 0.5 mol. % to about 10 mol. %of repeat units that comprise a saturated or ethylenically unsaturated alkylene group having at least 2 carbon atoms, or a cycloalkylene group, which has sulfur atoms or oxygen atoms in the chain and may include one or more substituents selected from the group consisting of alkyl cycloalkyl, aryl, aralkyl, heteroaryl, halogen or alkoxy. In one embodiment, a cyclic ether or acetal is used that can be introduced into the copolymer via a ring-opening reaction.

Preferred cyclic ethers or acetals are those of the formula:

in which x is 0 or 1 and R² is a C₂-C₄-alkylene group which, if appropriate, has one or more substituents which are C₁-C₄-akyl groups, or are C₁-C₄-alkoxy groups, and/or are halogen atoms, preferably chlorine atoms. Merely by way of example, mention may be made of ethylene oxide, propylene 1,2-oxide, butylene 1,2-oxide, butylene 1,3-oxide, 1,3-dioxane, 1,3-dioxolane, and 1,3-dioxepan as cyclic ethers, and also of linear oligo- or polyformals, such as polydioxolane or polydioxepan, as comonomers. It is particularly advantageous to use copolymers composed of from 99.5 to 95 mol. % of trioxane and of from 0.5 to 5 mol. %, such as from 0.5 to 4 mol. %, of one of the above-mentioned comonomers.

The polymerization can be effected as precipitation polymerization or in the melt. By a suitable choice of the polymerization parameters, such as duration of polymerization or amount of molecular weight regulator, the molecular weight and hence the MVR value of the resulting polymer can be adjusted.

In one embodiment, the polyoxymethylene polymer used in the polymer composition may contain a relatively high amount of reactive groups or functional groups in the terminal position. The reactive groups or functional groups can comprise any groups that are capable of forming a bond with a coupling agent. The reactive groups, for instance, may comprise —OH or —NH, groups.

In one embodiment, the polyoxymethylene polymer can have terminal hydroxyl groups, for example hydroxyethylene groups and/or hydroxyl side groups, in at least more than about 50% of all the terminal sites on the polymer. For instance, the polyoxymethylene polymer may have at least about 70%, such as at least about 80%, such as at least about 85% of its terminal groups be hydroxyl groups, based on the total number of terminal groups present. It should be understood that the total number of terminal groups present includes all side terminal groups.

In one embodiment, the polyoxymethylene polymer has a content of terminal hydroxyl groups of at least 15 mmol/kg, such as at least 18 mmol/kg, such as at least 20 mmol/kg. In one embodiment, the terminal hydroxyl group content ranges from 18 to 50 mmol/kg. In an alternative embodiment, the polyoxymethylene polymer may contain terminal hydroxyl groups in an amount less than 20 mmol/kg, such as less than 18 mmol/kg, such as less than 15 mmol/kg. For instance, the polyoxymethylene polymer may contain terminal hydroxyl groups in an amount from about 5 mmol/kg to about 20 mmol/kg, such as from about 5 mmol/kg to about 15 mmol/kg. For example, a polyoxymethylene polymer may be used that has a lower terminal hydroxyl group content but has a higher melt volume flow rate.

In addition to the terminal hydroxyl groups, the polyoxymethylene polymer may also have other terminal groups usual for these polymers. Examples of these are alkoxy groups, formate groups, acetate groups or aldehyde groups. According to one embodiment, the polyoxymethylene is a homo- or copolymer which comprises at least 50 mol-%, such as at least 75 mol-%, such as at least 90 mol-% and such as even at least 95 mol-% of —CH₂O-repeat units.

In addition to having a relatively high terminal hydroxyl group content, the polyoxymethylene polymer according to the present disclosure can also have a relatively low amount of low molecular weight constituents. As used herein, low molecular weight constituents (or fractions) refer to constituents having molecular weights below 10,000 dalton. In order to produce a polymer having the desired permeability requirements, the present inventors unexpectedly discovered that reducing the proportion of low molecular weight constituents can dramatically improve the permeability properties of the resulting material, when attached to an impact modifier. In this regard, the polyoxymethylene polymer contains low molecular weight constituents in an amount less than about 10% by weight, based on the total weight of the polyoxymethylene. In certain embodiments, for instance, the polyoxymethylene polymer may contain low molecular weight constituents in an amount less than about 5% by weight, such as in an amount less than about 3% by weight, such as even in an amount less than about 2% by weight.

In one embodiment, a polyoxymethylene polymer with hydroxyl terminal groups can be produced using a cationic polymerization process followed by solution hydrolysis to remove any unstable end groups. During cationic polymerization, a glycol, such as ethylene glycol can be used as a chain terminating agent. The cationic polymerization results in a bimodal molecular weight distribution containing low molecular weight constituents. In one particular embodiment, the low molecular weight constituents can be significantly reduced by conducting the polymerization using a heteropoly acid such as phosphotungstic acid as the catalyst. When using a heteropoly acid as the catalyst, for instance, the amount of low molecular weight constituents can be less than about 2 wt. %,

A heteropoly acid refers to polyacids formed by the condensation of different kinds of oxo acids through dehydration and contains a mono- or poly-nuclear complex ion wherein a hetero element is present in the center and the oxo acid residues are condensed through oxygen atoms. Such a heteropoly acid is represented by the formula:

H_(x)[MmM′nOz]_(y)H₂O

wherein

M represents an element selected from the group consisting of P, Si, Ge, Sn, As, Sb, U, Mn, Re, Cu, Ni, Ti, Co, Fe, Cr, Th or Ce,

M′ represents an element selected from the group consisting of W, Mo, V or Nb,

m is 1 to 10,

n is 6 to 40,

z is 10 to 100,

x is an integer of 1 or above, and

y is 0 to 50,

The central element (M) in the formula described above may be composed of one or more kinds of elements selected from P and Si and the coordinate element (M′) is composed of at least one element selected from W, Mo and V, particularly W or Mo.

Specific examples of heteropoly acids are phosphomolybdic acid, phosphotungstic acid, phosphomolybdotungstic acid, phosphomolybdovanadic acid, phosphomolybdotungstovanadic acid, phosphotungstovanadic acid, silicotungstic acid, silicomolybdic acid, silicomolybdotungstic acid, silicomolybdotungstovanadic acid and acid salts thereof. Excellent results have been achieved with heteropoly acids selected from 12-molybdophosphoric acid (H₃PMo₁₂O₄₀) and 12-tungstophosphoric acid (H₃PW₁₂O₄₀) and mixtures thereof.

The heteropoly acid may be dissolved in an alkyl ester of a polybasic carboxylic acid. It has been found that alkyl esters of polybasic carboxylic acid are effective to dissolve the heteropoly acids or salts thereof at room temperature (25° C.).

The alkyl ester of the polybasic carboxylic acid can easily be separated from the production stream since no azeotropic mixtures are formed. Additionally, the alkyl ester of the polybasic carboxylic acid used to dissolve the heteropoly acid or an acid salt thereof fulfills the safety aspects and environmental aspects and, moreover, is inert under the conditions for the manufacturing of oxymethylene polymers.

Preferably the alkyl ester of a polybasic carboxylic acid is an alkyl ester of an aliphatic dicarboxylic acid of the formula:

(ROOC)—(CH₂)n-(COOR')

wherein

n is an integer from 2 to 12, preferably 3 to 6 and

R and R′ represent independently from each other an alkyl group having 1 to 4 carbon atoms, preferably selected from the group consisting of methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl and tert.-butyl.

In one embodiment, the polybasic carboxylic acid comprises the dimethyl or diethyl ester of the above-mentioned formula, such as a dimethyl adipate (DMA).

The alkyl ester of the polybasic carboxylic acid may also be represented by the following formula:

(ROOC)₂—CH—(CH₂)m-CH—(COOR′)₂

wherein

m is an integer from 0 to 10, preferably from 2 to 4 and

R and R′ are independently from each other alkyl groups having 1 to 4 carbon atoms, preferably selected from the group consisting of methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl and tert.-butyl.

Particularly preferred components which can be used to dissolve the heteropoly acid according to the above formula are butantetracarboxylic acid tetratethyl ester or butantetracarboxylic acid tetramethyl ester.

Specific examples of the alkyl ester of a polybasic carboxylic acid are dimethyl glutaric acid, dimethyl adipic acid, dimethyl pimelic acid, dimethyl suberic acid, diethyl glutaric acid, diethyl adipic acid, diethyl pimelic acid, diethyl suberic acid, diemethyl phthalic acid, dimethyl isophthalic acid, dimethyl terephthalic acid, diethyl phthalic acid, diethyl isophthalic acid, diethyl terephthalic acid, butantetracarboxylic acid tetramethylester and butantetracarboxylic acid tetraethylester as well as mixtures thereof. Other examples include dimethylisophthalate, diethylisophthalate, dimethylterephthalate or diethylterephthalate.

Preferably, the heteropoly acid is dissolved in the alkyl ester of the polybasic carboxylic acid in an amount lower than 5 wt. %, preferably in an amount ranging from 0.01 to 5 wt. %, wherein the weight is based on the entire solution.

In some embodiments, the polymer composition of the present disclosure may contain other polyoxymethylene homopolymers and/or polyoxymethylene copolymers. Such polymers, for instance, are generally unbranched linear polymers which contain at least 80%, such as at least 90%, oxymethylene units.

The polyoxymethylene polymer can have any suitable molecular weight. The molecular weight of the polymer, for instance, can be from about 4,000 grams per mole to about 20,000 g/mol. In other embodiments, however, the molecular weight can be well above 20,000 g/mol, such as from about 20,000 g/mol to about 100,000 g/mol.

The polyoxymethylene polymer present in the composition can generally melt flow index (MFI) ranging from about 1 to about 50 g/10 min, as determined according to ISO 1133 at 190° C. and 2.16 kg, though polyoxymethylenes having a higher or lower melt flow index are also encompassed herein. For example, the polyoxymethylene polymer may be a low or mid-molecular weight polyoxymethylene that has a melt flow index of greater than about 5 g/10 min, greater than about 10 g/10 min, or greater than about 15 g/10 min. The melt flow index of the polyoxymethylene polymer can be less than about 25 g/10 min, less than about 20 g/10 min, less than about 18 g/10 min, less than about 15 g/10 min, less than about 13 g/10 min, or less than about 12 g/10 min. The polyoxymethylene polymer may for instance be a high molecular weight polyoxymethylene that has a melt flow index of less than about 5 g/10min, less than about 3 g/10min, or less than about 2 g/10 min.

Suitable commercially available polyoxymethylene polymers are available under the trade name Hostaform® (HF) by Celanese/Ticona.

The polyoxymethylene polymer may be present in the polyoxymethylene polymer composition in an amount of at least 50 wt. %, such as at least 60 wt. %, such as at least 70 wt. %, such as at least 80 wt. %, such as at least 85 wt. %, such as at least 90 wt. %, such as at least 95 wt. %, In general, the polyoxymethylene polymer is present in an amount of less than about 100 wt. %, such as less than about 99 wt. %, such as less than about 97 wt. %, wherein the weight is based on the total weight of the polyoxymethylene polymer composition.

Reinforcing Fibers

In one embodiment, the polymer composition may optionally contain reinforcing fibers.

Reinforcing fibers of which use may advantageously be made are mineral fibers, such as glass fibers, polymer fibers, in particular organic high-modulus fibers, such as aramid fibers, or metal fibers, such as steel fibers, or carbon fibers or natural fibers, fibers from renewable resources.

These fibers may be in modified or unmodified form, e.g. provided with a sizing, or chemically treated, in order to improve adhesion to the plastic. Glass fibers are particularly preferred.

Glass fibers are provided with a sizing to protect the glassfiber, to smooth the fiber but also to improve the adhesion between the fiber and the matrix material. A sizing usually comprises silanes, film forming agents, lubricants, wetting agents, adhesive agents optionally antistatic agents and plasticizers, emulsifiers and optionally further additives.

Specific examples of silanes are aminosilanes, e.g. 3-trimethoxysilylpropylamine, N-(2-aminoethyl)-3-aminopropyltrimethoxy-silane, N-(3-trimethoxysilanylpropyl)ethane-1,2-diamine, 3-(2-aminoethyl-amino)propyltrimethoxysilane, N-[3-(trimethoxysily)propyl]-1,2-ethane-diamine.

Film forming agents are for example polyvinylacetates, polyesters and polyurethanes. Sizings based on polyurethanes may be used advantageously.

The reinforcing fibers may be compounded into the polyoxymethylene matrix, for example in an extruder or kneader. However, the reinforcing fibers may also advantageously take the form of continuous-filament fibers sheathed or impregnated with the polyoxymethylene molding composition in a process suitable for this purpose, and then processed or wound up in the form of a continuous strand, or cut to a desired pellet length so that the fiber lengths and pellet lengths are identical. An example of a process particularly suitable for this purpose is the pultrusion process.

According to the invention, the long-fiber-reinforced polyoxymethylene molding composition may be a glass-fiber bundle which has been sheathed with one or more layers of the polyoxymethylene matrix polymer in such a way that the fibers have not been impregnated and mixing of the fibers and the polyacetal matrix polymer does not take place until processing occurs, for example injection molding. However, the fibers have advantageously been impregnated with the polyacetal matrix polymer.

According to a preferred embodiment, the molding composition of the present invention comprises at least one reinforcing fiber which is a mineral fiber, preferably a glass fiber, more preferably a coated or impregnated glass fiber. Glass fibers which are suitable for the molding composition of the present invention are commercially available, e.g. Johns Manville, ThermoFlow®Chopped Strand 753, OCV Chopped Strand 408 A, Nippon Electric Glass Co. (NEG) Chopped Strand T-651.

Fiber diameters can vary depending upon the particular fiber used and whether the fiber is in either a chopped or a continuous form. The fibers, for instance, can have a diameter of from about 5 μm to about 100 μm, such as from about 5 μm to about 50 μm, such as from about 5 μm to about 15 μm. When present, the respective composition may contain reinforcing fibers in an amount of at least 1 wt. %, such as at least 5 wt. %, such as at least 7 wt. %, such as at least 10 wt. %, such as at least 15 wt. % and generally less than about 50 wt. %, such as less than about 45 wt. %, such as less than about 40 wt. %, such as less than about 30 wt. %, such as less than about 20 wt. %, wherein the weight is based on the total weight of the respective polyoxymethylene polymer composition.

Coupling Agent

In one embodiment, a coupling agent may be present. Coupling agents used include polyfunctional coupling agents, such as trifunctional or bifunctional agents. A suitable coupling agent is a polyisocyanate such as a diisocyanate. The coupling agent may provide a linkage between the polyoxymethylene polymer and the reinforcing fiber and/or sizing material coated on the reinforcing fiber. Generally, the coupling agent is present in an amount of at least about 0.1 wt. %, such as at least about 0.2 wt. % such as at least about 0.3 wt. % and less than about 5 wt. %, such as less than about 3 wt. %, such as less than about 1.5 wt. %. Alternatively, the composition may also be substantially free of any coupling agents such as less than about 0.2 wt. %, such as less than about 0.1 wt. %, such as less than about 0.05 wt. %, such as less than about 0.01 wt. %, such as about 0 wt. %.

A suitable coupling agent is a polyisocyanate, preferably organic diisocyanate, more preferably a polyisocyanate selected from the group consisting of aliphatic diisocyanates, cycloaliphatic diisocyanates, aromatic diisocyanates and mixtures thereof.

Preferred are polyfunctional coupling agents, such as trifunctional or bifunctional agents.

Preferably, the polyisocyanate is a diisocyanate or a triisocyanate which is more preferably selected from 2,2′-,2,4′-, and 4,4′-diphenylmethane diisocyanate (MDI); 3,3′-dimethyl-4,4′-biphenylene diisocyanate (TODI); toluene diisocyanate (TDI); polymeric MDI; carbodiimide-modified liquid 4,4′-diphenylmethane diisocyanate; para-phenylene diisocyanate (PPDI); meta-phenylene diisocyanate (MPDI); triphenyl methane-4,4′- and triphenyl methane-4,4″-triisocyanate; naphthylene-1,5-diisocyanate; 2,4′-, 4,4′-, and 2,2-biphenyl diisocyanate; polyphenylene polymethylene polyisocyanate (PMDI) (also known as polymeric PMDI); mixtures of MDI and PMDI; mixtures of PMDI and TDI; ethylene diisocyanate; propylene-1,2-diisocyanate; trimethylene diisocyanate; butylenes diisocyanate; bitolylene diisocyanate; tolidine diisocyanate; tetramethylene-1,2-dilsocyanate; tetramethylene-1,3-diisocyanate; tetramethylene-1,4-diisocyanate; pentamethylene diisocyanate; 1,6-hexamethylene diisocyanate (HDI); octamethylene diisocyanate; decamethylene diisocyanate; 2,2,4-trimethylhexamethylene diisocyanate; 2,4,4-timethylhexamethylene diisocyanate; dodecane-1,12-diisocyanate; dicyclohxylmethane diisocyanate; cyclobutane-1,3-diisocyanate, cyclohexane-1,2-diisocyanate; cyclohexane-1,3-diisocyanate; cyclohexane-1,4-diisocyanate; diethylidene diisocyanate; methylcyclohexylene diisocyanate (HTDI); 2,4-methylcyclohexane diisocyanate; 2,6-methyloyclohexane diisocyanate; 4,4′-dicyclohexyl diisocyanate; 2,4′-dicyclohexyl diisocyanate; 1,3,5-cyclohexane triisocyanate: isocyanatomethylcyclohexane isocyanate; 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane: isocyanatoethylcyclohexane isocyanate; bis(isocyanatomethyl)-cyclohexane diisocyanate: 4,′-bis(isocyanatomethyl) dicyclohexane; 2,4′-bis(isocyanatomethyl)dicyclohexane; isophorone diisocyanate (IPDI); dimeryl diisocyanate, dodecane-1,12-diisocyanate, 1,10-decamethylene diisocyanate, cyclohexylene-1,2-diisocyanate, 1,10-decamethylene diisocyanate, 1-chlorobenzene-2,4-diisocyanate, furfurylidene diisocyanate, 2,4,4-trimethyl hexamethylene diisocyanate, 2,2,4-trimethyl hexamethylene diisocyanate, dodecamethylene diisocyanate, 1,3-cyclopentane diisocyanate, 1,3-cyclohexane diisocyanate, 1,3-cyclobutane diisocyanate, 1,4-cyclohexane diisocyanate, 4,4′-methylenebis(cyclohexyl isocyanate), 4,4′-methylenebis(phenyl isocyanate), 1-methyl-2,4-cyclohexane diisocyanate, 1-methyl-2,6-cyclohexane diisocyanate, 1,3-bis (isocyanato-methyl)cyclohexane, 1,6-chisocyanato-2,2,4,4-tetra-methylhexane, 1,6-diisocyanato-2,4,4-tetra-trimethylhexane, trans-cyclohexane-1,4-diisocyanate, 3-isocyanato-methyl-3,5,5-trimethyloyclo-hexyl isocyanate, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane, cyclo-hexyl isocyanate, dicyclohexylmethane 4,4′-diisocyanate, 1,4-bis(isocyanatomethyl)cyclohexane, m-phenylene diisocyanate, m-xylylene diisocyanate, m-tetramethylxylylene diisocyanate, p-phenylene diisocyanate, p,p′-biphenyl diisocyanate, 3,3′-dimethyl-4,4′-biphenylene diisocyanate, 3,3′-dimethoxy-4,4° -biphenylene diisocyanate, 3,3′-diphenyl-4,4′-biphenylene diisocyanate, 4,4′-biphenylene diisocyanate, 3,3′-dichloro-4,4′-biphenylene diisocyanate, 1,5-naphthalene diisocyanate, 4-chloro-1,3-phenylene diisocyanate, 1,5-tetrahydronaphthalene diisocyanate, metaxylene diisocyanate, 2,4-toluene diisocyanate, 2.4′-diphenylmethane diisocyanate, 2,4-chlorophenylene diisocyanate, 4,4′-diphenylmethane diisocyanate, p,p′-diphenylmethane diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 2.2-diphenylpropane-4,4′-diisocyanate, 4,4′-toluidine diisocyanate, dianidine diisocyanate, 4,4′-diphenyl ether diisocyanate, 1,3-xylylene diisocyanate, 1,4-naphthylene diisocyanate, azobenzene-4,4′-diisocyanate, diphenyl sulfone-4,4′-dilsocyanate, or mixtures thereof.

Especially preferred are aromatic polyisocyanates, such as 4,4′-diphenylmethane diisocyanate (MDI).

Tribological Modifiers

According to the present disclosure, the polyoxymethylene polymer composition and the polymer article comprising the polyoxymethylene polymer composition may comprise at least one tribological modifier. For instance, the polyoxymethylene polymer composition may comprise an ultra-high molecular weight silicone.

In general, the UHMW-Si may have an average molecular weight of greater than about 100,000 g/mol, such as greater than about 200,000 g/mol, such as greater than about 300,000 g/mol, such as greater than 500,000 g/mol and less than about 5,000,000 g/mol, such as less than about 3,000,000 g/mol, such as less than about 2,000,000 g/mol, such as less than about 1,000,000 g/mol, such as less than about 500,000 g/mol, such as less than about 300,000 g/mol. Generally, the UHMW-Si may have a kinematic viscosity at 40° C. measured according to DIN 51562 of greater than about 100,000 mm²s⁻¹, such as greater than about 200,000 mm²s⁻¹, such as greater than about 1,000,000 mm²s⁻¹, such as greater than about 5,000,000 mm²s⁻¹, such as greater than about 10,000,000 mm²s⁻¹, such as greater than about 15,000,000 mm²s⁻¹ and less than about 50,000,000 mm²s⁻¹, such as less than about 25,000,000 mm²s⁻¹, such as less than about 10,000,000 mm²s⁻¹, such as less than about 1,000,000 mm²s⁻¹, such as less than about 500,000 mm²s⁻¹, such as less than about 200,000 mm²s⁻¹.

The UHMW-Si may comprise a siloxane such as a polysiloxane or polyorganosiloxane. In one embodiment, the UHMW-Si may comprise a dialkylpolysiloxane such as a dimethylsiloxane, an alkylarylsiloxane such as a phenylmethylsilaoxane, or a diarylsiloxane such as a diphenylsiloxane, or a homopolymer thereof such as a polydimethylsiloxane or a polymethylphenylsiloxane, or a copolymer thereof with the above molecular weight and/or kinematic viscosity requirements. The polysiloxane or polyorganosiloxane may also be modified with a substituent such as an epoxy group, a hydroxyl group, a carboxyl group, an amino group or a substituted amino group, an ether group, or a meth(acryloyl) group in the end or main chain of the molecule. The UHMW-Si compounds may be used singly or in combination. Any of the above UHMW-Si compounds may be used with the above molecular weight and/or kinematic viscosity requirements

The UHMW-Si may be added to the polyoxymethylene polymer composition as a masterbatch wherein the UHMW-Si is dispersed in a polyoxymethylene polymer and the masterbatch is thereafter added to another polyoxymethylene polymer. The masterbatch may comprise from about 10 wt. % to about 50 wt. %, such as from about 35 wt. % to about 45 wt. %, such as about 40 wt. % of an UHMW-Si.

The UHMW-Si may be present in the polyoxymethylene polymer composition in an amount of at greater than about 0 wt. %, such as at greater than about 0.1 wt. %, such as at greater than about 0.5 wt. %, such as at greater than about 0.75 wt. %, such as at greater than about 1 wt. %, such as at greater than about 2 wt. %, such as at greater than about 2.5 wt. % and generally less than about 10 wt. %, such as less than about 6 wt. %, such as less than about 5 wt. %, such as less than about 4 wt. %, such as less than about 3.5 wt. %, such as less than about 3 wt. %, wherein the weight is based on the total weight of the polyoxymethylene polymer composition.

In one embodiment, boron nitride may be used to modify the polyoxymethylene polymer. Boron nitride has been found to be particularly beneficial in improving the tribological properties and reducing the coefficient of friction of polyoxymethylene. Boron nitride exists in a variety of different crystalline forms (e.g., h-BN—hexagonal, c-BN—cubic or spharlerite, and w-BN—wurtzite). In one embodiment, hexagonal boron nitride may be used in the composition. Not to be limited by theory, the h-BN may promote lubricity due to its layered structure and weak secondary forces between adjacent layers allowing or easy sliding of the layers. The boron nitride may have a particle size ranging from about 0.5 μm to about 10 μm, such as from about 1 μm to about 6 μm, such as about 1.5 μm or 5 μm. In one embodiment, the boron nitride may have a particle size of from about 0.5 μm to about 2.5 μm such as from about 0.5 μm to about 1.5 μm. In another embodiment, the boron nitride may have a particle size of from about 3 μm to about 7 μm such as from about 4 μm to about 6 μm. The boron nitride may be present in the polyoxymethylene polymer composition in an amount of at least about 0 wt. %, such as at least about 0.1 wt. %, such as at least about 0.5 wt. %, such as at least about 0.75 wt. %, such as at least about 1 wt. %, such as at least about 2 wt. % and generally less than about 10 wt. %, such as less than about 5 wt. %, such as less than about 2.5 wt. %, such as less than about 2 wt. %, wherein the weight is based on the total weight of the polyoxymethylene polymer composition.

According to another embodiment, boron nitride, such as hexagonal-boron nitride, and UHMW-Si may be utilized in combination to modify the polyoxymethylene polymer. The present inventors have discovered that when both tribological modifiers are used simultaneously, the combination provides a synergistic effect with a resulting polymer composition that exhibits improved tribological properties while maintaining or even improving the mechanical properties. In such embodiments, the boron nitride and UHMW-Si may be utilized in the polyoxymethylene polymer composition in the amounts disclosed above.

According to another embodiment, UHMW-Si may be utilized in combination with PTFE. The present inventors have discovered that when both tribological modifiers are used simultaneously, the combination may provide a synergistic effect with a resulting polymer composition that exhibits improved tribological properties while maintaining or even improving the mechanical properties. In one embodiment, the PTFE may be in the form of a powder. In another embodiment, the PTFE may be in the form of a fiber. When used in combination with UHMW-Si, in one embodiment, the amount of PTFE may be present in an amount of at least 0.1 wt. %, such as at least 1 wt. %, such as at least 5 wt. %, such as at least 10 wt. %, such as at least 15 wt. % and generally less than about 50 wt. %, such as less than about 40 wt. %, such as less than about 30 wt. %, such as less than about 25 wt. %, such as less than about 15 wt. %, such as less than about 10 wt. %. The reduction in PTFE may still provide a composition with desired tribological properties. The PTFE and UHMW-Si may be utilized in the polyoxymethylene polymer composition in the amounts disclosed above.

According to the present disclosure, various other tribological modifiers may be incorporated into the polyoxymethylene polymer composition. These tribological modifiers may include, for instance, calcium carbonate particles, ultrahigh-molecular-weight polyethylene (UHMW-PE) particles, stearyl stearate particles, silicone oil, a polyethylene wax, an amide wax, wax particles comprising an aliphatic ester wax comprised of a fatty acid and a monohydric alcohol, a graft copolymer with an olefin polymer as a graft base, or a combination thereof. These tribological modifiers include the following:

(1) From 0.1-50 wt. %, such as from 1-25 wt. %, of a calcium carbonate particle such as a calcium carbonate (chalk) powder.

(2) From 0.1-50 wt. %, such as from 1-25 wt. %, such as from 2.5-20 wt. %, such as from 5 to 15 wt. %, of an ultrahigh-molecular-weight polyethylene (UHMW-PE) powder. UHMW-PE can be employed as a powder, in particular as a micro-powder. The UHMW-PE generally has a mean particle diameter D₅₀ (volume based and determined by light scattering) in the range of 1 to 5000 μm, preferably from 10 to 500 μm, and particularly preferably from 10 to 150 μm such as from 30 to 130 μm, such as from 80 to 150 μm, such as from 30 to 90 μm.

The UHMW-PE can have an average molecular weight of higher than 1.0·10⁶ g/mol, such as higher than 2.0·10⁶ g/mol, such as higher than 4.0·10⁶ g/mol, such as ranging from 1.0·10⁶ g/mol to 15.0·10⁶ g/mol, such as from 3.0·10⁶ g/mol to 12.0·10⁶ g/mol, determined by viscosimetry. Preferably, the viscosity number of the UHMW-PE is higher than 1000 ml/g, such as higher than 1500 ml/g, such as ranging from 1800 mi/g to 5000 ml/g, such as ranging from 2000 ml/g to 4300 ml/g (determined according to ISO 1628, part 3; concentration in decahydronaphthalin: 0.0002 g/ml).

(3) From 0.1-10 wt. %, such as from 0.1-5 wt. %, such as from 0.5-3 wt. %, of stearyl stearate,

(4) From 0.1-10 wt. %, such as from 0.5-5 wt. such as from 0.8-2 wt. %, of a silicone oil. Alternatively, in one embodiment, the composition may be substantially free of silicone oil, such as less than about 0.1 wt. %, such as less than about 0.05 wt. %, such as less than about 0.01 wt. %, such as about 0 wt. %. In another embodiment, the composition may not comprise a combination of silicone oil and UHMW-Si alone. In such embodiments, the composition may comprise UHMW-Si, silicone oil, and another tribological modifier, such as hexagonal boron nitride or PTFE.

When silicone oil is present in the composition, the silicone oil may have an average molecular weight of at least about 5,000 g/mol, such as at least about 20,000 g/mol, such as at least about 50,000 g/mol and generally less than about 100,000 g/mol, such as less than about 75,000 g/mol, such as less than about 50,000 g/mol. The silicone oil may have a kinematic viscosity at 40° C. measured according to DIN 51562 of greater than about 100 mm²s⁻¹, such as greater than about 5,000 mm²s⁻¹, such as greater than about 15,000 mm²s⁻¹ and generally less than about 100,000 mm²s⁻¹, such as less than about 50,000 mm²s⁻¹, such as less than about 25,000 mm²s⁻¹, such as less than about 15,000 mm²s⁻¹. The silicone oil may comprise a liquid polysiloxane such as a polydimethylsiloxane at a room temperature of 25° C. with the above molecular weight and/or kinematic viscosity specifications.

(5) From 0.1-5 wt. %, such as from 0.5-3 wt. %, of a polyethylene wax, such as an oxidized polyethylene wax.

(6) From 0.1-5 wt. %, such as from 0.2-2 wt. %, of an amide wax.

(7) From 0.1-5 wt. %, such as from 0.5-3 wt. %, of an aliphatic ester wax composed of a fatty acid and of a monohydric alcohol.

(8) From 0.1-50 wt. %, such as from 1-25 wt. %, such as from 2-10 wt. % by weight of a graft copolymer which has an olefin polymer as a graft base and, grafted on this, at least one vinyl polymer or one ether polymer, and/or a graft copolymer which has an elastomeric core based on polydienes and a hard graft envelope composed of (meth)acrylates and/or of (meth)acrylonitriles. A suitable graft base can be any olefin homopolymer (e.g., polyethylene or polypropylene) or copolymer or copolymers derived from copolymerizable ethylenically unsaturated monomers (e.g, ethylenepropylene copolymers, ethylene-1-butene copolymers, ethylene/glycidyl (meth)acrylate copolymers). Suitable graft monomers are any of the ethylenically unsaturated monomers having a polar group or other graftable monomers having polar groups that modify the polarity of the essentially non-polar graft base (e.g. ethylenically unsaturated carboxylic acids such as (meth)acrylic acid and derivatives thereof in combination with acrylonitrile or styrene/acrylonitrile, if appropriate). In one embodiment, the graft copolymer may comprise a polyethylene or polypropylene graft base grafted with acrylonitrile or with styrene/acrylonitrile.

(9) From 0.1-50 wt. %, such as from 1-25 wt. % of a polytetrafluoroethylene powder.

(10) From 0.1-10 wt. %, such as from 0.2-5 wt. % of a molybdenum disulfide powder.

In general, the tribological modifiers improve the tribological properties of the polyoxymethylene polymer composition by reducing the coefficient of friction and wear when contacted with another surface or counter-material. In addition, in some instances, the tribological modifiers may even improve the mechanical properties of the polyoxymethylene polymer composition and a polymer article produced therefrom.

According to the present disclosure, tribological modifiers improve the tribological properties of the polyoxymethylene polymer compositions and polymer articles produced therefrom without the need for an external lubricant, such as water-based or PTFE based external lubricants, when utilized in tribological applications. An external lubricant may be a lubricant that is applied to a polymer article or polyoxymethylene based system of the present disclosure. In one embodiment, an external lubricant may not be associated with the polyoxymethylene polymer composition or polymer article such that the external lubricant is not present on a surface of the polyoxymethylene polymer composition or polymer article. In another embodiment, an external lubricant may be utilized with the polyoxymethylene polymer composition and polymer article of the present disclosure.

Other Additives

The polymer composition of the present disclosure may also contain other known additives such as, for example, antioxidants, formaldehyde scavengers, acid scavengers, UV stabilizers or heat stabilizers, reinforcing fibers. In addition, the compositions can contain processing auxiliaries, for example adhesion promoters, lubricants, nucleants, demolding agents, fillers, or antistatic agents and additives which impart a desired property to the compositions and articles or parts produced therefrom.

In one embodiment, an ultraviolet light stabilizer may be present. The ultraviolet light stabilizer may comprise a benzophenone, a benzotriazole, or a benzoate. The UV light absorber, when present, may be present in the polymer composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, a formaldehyde scavenger, such as a nitrogen-containing compound, may be present. Mainly, of these are heterocyclic compounds having at least one nitrogen atom as hetero atom which is either adjacent to an amino-substituted carbon atom or to a carbonyl group, for example pyridine, pyrimidine, pyrazine, pyrrolidone, aminopyridine and compounds derived therefrom. Other particularly advantageous compounds are triamino-1,3,5-triazine (melamine) and its derivatives, such as melamine-formaldehyde condensates and methylol melamine. Oligomeric polyamides are also suitable in principle for use as formaldehyde scavengers. The formaldehyde scavenger may be used individually or in combination.

Further, the formaldehyde scavenger may be a guanarnine compound which may include an aliphatic guanamine-based compound, an alicyclic guanamine-based compound, an aromatic guanamine-based compound, a hetero atom-containing guanamine-based compound, or the like. The formaldehyde scavenger may be present in the polymer composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, an acid scavenger may be present. The acid scavenger may comprise, for instance, an alkaline earth metal salt. For instance, the acid scavenger may comprise a calcium salt, such as a calcium citrate. The acid scavenger may be present in an amount of at least about 0.001 wt. %, such as at least about 0.005 wt. %, such as at least about 0.0075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, a nucleant may be present. The nucleant may increase crystallinity and may comprise an oxymethylene terpolymer. In one particular embodiment, for instance, the nucleant may comprise a terpolymer of butanediol diglycidyl ether, ethylene oxide, and trioxane. The nucleant may be present in the composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.1 wt. % and less than about 2 wt. %, such as less than about 1.5 wt. %, such as less than about 1 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, an antioxidant, such as a sterically hindered phenol, may be present. Examples which are available commercially, are pentaerythrityl tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], triethylene glycol bis[3-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate], 3,3′-bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionohydrazide], and hexamethylene glycol bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate]. The antioxidant may be present in the polymer composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, lights stabilizers, such as sterically hindered amines, may be present in addition to the ultraviolet light stabilizer. Hindered amine light stabilizers that may be used include oligomeric hindered amine compounds that are N-methylated. For instance, hindered amine light stabilizer may comprise a high molecular weight hindered amine stabilizer. The light stabilizers, when present, may be present in the polymer composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, lubricants may be present. The lubricant may comprise a polymer wax composition. Further, in one embodiment, a polyethylene glycol polymer (processing aid) may be present in the composition. The polyethylene glycol, for instance, may have a molecular weight of from about 1000 to about 5000, such as from about 3000 to about 4000. In one embodiment, for instance, PEG-75 may be present. In another embodiment, a fatty acid amide such as ethylene bis(stearamide) may be present. Lubricants may generally be present in the polymer composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, a compatibilizer, such as a phenoxy resin, may be present. Generally, the phenoxy resin may be present in the composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.075 wt. % and less than about 1 wt. %, such as less than about 0.75 wt. %, such as less than about 0.5 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

In one embodiment, a colorant may be present. Colorants that may be used include any desired inorganic pigments, such as titanium dioxide, ultramarine blue, cobalt blue, and other organic pigments and dyes, such as phthalocyanines, anthraquinnones, and the like. Other colorants include carbon black or various other polymer-soluble dyes. The colorant may be present in the composition in an amount of at least about 0.01 wt. %, such as at least about 0.05 wt. %, such as at least about 0.1 wt. % and less than about 5 wt. %, such as less than about 2.5 wt. %, such as less than about 1 wt. %, wherein the weight is based on the total weight of the respective polymer composition.

Polymer Articles

The compositions of the present disclosure can be compounded and formed into a polymer article using any technique known in the art. For instance, the respective composition can be intensively mixed to form a substantially homogeneous blend. The blend can be melt kneaded at an elevated temperature, such as a temperature that is higher than the melting point of the polymer utilized in the polymer composition but lower than the degradation temperature. Alternatively, the respective composition can be melted and mixed together in a conventional single or twin screw extruder. Preferably, the melt mixing is carried out at a temperature ranging from 100 to 280° C., such as from 120 to 260° C., such as from 140 to 240° C. or 180 to 220° C.

After extrusion, the compositions may be formed into pellets. The pellets can be molded into polymer articles by techniques known in the art such as injection molding, thermoforming, blow molding, rotational molding and the like. According to the present disclosure, the polymer articles demonstrate excellent tribological behavior and mechanical properties. Consequently, the polymer articles can be used for several applications where low wear and excellent gliding properties are desired.

Polymer articles include any moving articles or moldings that are in contact with another surface and may require high tribological requirements. For instance, polymer articles include articles for the automotive industry, especially housings, latches such as rotary latches, window winding systems, wiper systems, pulleys, sun roof systems, seat adjustments, levers, bushes, gears, gear boxes, claws, pivot housings, wiper arms, brackets or seat rail bearings, zippers, switches, cams, rollers or rolling guides, sliding elements or glides such as sliding plates, conveyor belt parts such as chain elements and links, castors, fasteners, levers, conveyor system wear strips and guard rails, medical equipment such as medical inhalers and injectors. An almost limitless variety of polymer articles may be formed from the polymer compositions of the present disclosure.

Properties

Utilizing the polyoxymethylene polymer composition and polymer article produced therefrom according to the present disclosure provides compositions and articles with improved tribological properties. According to the present disclosure, the tribological properties are generally measured by the coefficient of friction.

In general, static friction is the friction between two or more surfaces that are not moving relative to each other (ie., both objects are stationary). In general, dynamic friction occurs when two objects are moving relative to each other (ie., at least one object is in motion or repeated back and forth motion). In addition, stick-slip is generally known as a phenomenon caused by continuous alternating between static and dynamic friction.

According to the present disclosure, the composition and polymer article may exhibit a static coefficient of friction against another surface, as determined according to VDA 230-206, of greater than about 0.01, such as greater than about 0.02, such as greater than about 0.03, such as greater than about 0.04, such as greater than about 0.05, such as greater than about 0.06 and generally less than about 0.2, such as less than about 0.18, such as less than about 0.15, such as less than about 0.12, such as less than about 0.1, such as less than about 0.9, such as less than about 0.8, such as less than about 0.7, such as less than about 0.6.

According to the present disclosure, the composition and polymer article may exhibit a dynamic coefficient of friction against another surface, as determined according to VDA 230-206, of greater than about 0.001, such as greater than about 0.01, such as greater than about 0.02, such as greater than about 0.03, such as greater than about 0.04, such as greater than about 0.05, such as greater than about 0.06 and generally less than about 0.2, such as less than about 0.18, such as less than about 0.15, such as less than about 0.12, such as less than about 0.1, such as less than about 0.09, such as less than about 0.08, such as less than about 0.07, such as less than about 0.06. In one embodiment, when the polymer composition contains a polyoxymethylene polymer containing functional groups, reinforcing fibers, a coupling agent, and an ultra-high molecular weight silicone, the polymer composition may exhibit a dynamic coefficient of friction of less than about 0.07, such as less than about 0.06, such as even less than about 0.05.

In addition, the effect of sliding speed on the dynamic coefficient of friction was also measured at speeds of 0.1 mm/s, 1 mm/s, 10 mm/s, and 100 mm/s. This test method utilizes a ball-on-prism configuration where a ball made of a plastic or metal rotates uni-directionally against the plate of a counter material. At a speed of 0.1 mm/s, the dynamic coefficient of friction against another surface is greater than about 0.02, such as greater than about 0.03, such as greater than about 0.04, such as greater than about 0.05 and generally less than about 0.1, such as less than about 0.08, such as less than about 0.07, such as less than about 0.06. At a speed of 1 mm/s, the dynamic coefficient of friction against another surface is greater than about 0.02, such as greater than about 0.03, such as greater than about 0.04, such as greater than about 0.05 generally less than about 0.1, such as less than about 0.08, such as less than about 0.07, such as less than about 0.06. At a speed of 10 mm/s, the dynamic coefficient of friction against another surface is greater than about 0.03, such as greater than about 0.04, such as greater than about 0.05, such as greater than about 0.06 and generally less than about 0.15, such as less than about 0.12, such as less than about 0.1, such as less than about 0.09, such as less than about 0.08, such as less than about 0.07, At a speed of 100 mm/s, the dynamic coefficient of friction against another surface is greater than about 0.05, such as greater than about 0.07, such as greater than about 0.08, such as greater than about 0.09 and generally less than about 0.17, such as less than about 0.15, such as less than about 0.12, such as less than about 0.1, such as less than about 0.09, such as less than about 0.08.

In one embodiment, the above static coefficient of friction and dynamic coefficient of friction values and effect of sliding speed on the dynamic coefficient of friction are exhibited between the composition or polymer article and various counter-materials. For instance, the above values may be exhibited between the composition or polymer article and a polyester surface such as a polyethylene terephthalate surface. In another embodiment, the above values may be exhibited between the composition or polymer article and a polyacetal surface, a metal surface such as a steel surface, or a polyolefin surface such as a polypropylene surface or a polyethylene surface such as an ultra-high molecular weight polyethylene surface.

In one embodiment, the composition and articles of the present disclosure may exhibit improved wear properties when compared to polyoxymethylene compositions and articles that are not modified with a tribological modifier. The wear tests may be conducted utilizing a steel shaft, a shaft diameter of 65 mm, a roughness of 0.8 μm, a load of 3.1 N, a sliding velocity of 136 m/min, a test duration of 60 h, and a distance of 490 km. The compositions of the present disclosure may exhibit at least 20% reduced wear, such as at least 40% reduced wear, such as at least 50% reduced wear, such as at least 60% reduced wear, such as at least 80% reduced wear and less than about 100% reduced wear, such as less than about 90% reduced wear, such as less than about 80% reduced wear, when compared to the wear of a polyoxymethylene polymer that is not modified with a tribological modifier.

During the above test, a track may be formed in the polymer specimen due to abrasion. The length of the track can then be measured. Polymer compositions made according to the present disclosure may exhibit an abrasion of less than 2 mm, such as less than 1.5 mm, such as less than 1.25 mm, such as less than 1 mm, such as less than 0.75 mm, such as less than 0.5 mm, such as less than 0.25 mm. In fact, in one embodiment, the polymer composition of the present disclosure may exhibit an abrasion of 0 mm.

While the polyoxymethylene polymer composition and polymer articles produced therefrom of the present invention provide improved tribological properties, the compositions and articles may also exhibit improved mechanical properties. For instance, the modulus of elasticity, determined according to ISO Test No. 527, of the composition or polymer article may be greater than about 2000 MPa, such as greater than about 2200 MPa, such as greater than about 2400 MPa, such as greater than about 2500 MPa, such as greater than about 2600 MPa and generally less than about 10000 MPa, such as less than about 7500 MPa, such as less than about 5000 MPa, such as less than about 4000 MPa, such as less than about 3500 MPa, such as less than about 3000 MPa.

In one embodiment, the polymer article or molded polymer article may have topographical features that may provide surface characteristics and/or surface roughness on at least one surface of the article. For instance, the features may be ridges, valleys, protrusions, and the like on the surface of the article. These features may be present at the nanoscale or microscale level. Not to be limited by theory, the surface roughness may be produced during the molding of specific polymer articles. Surface roughness may also be produced depending on the particular additives present in the composition.

When in contact with a counter material, the surface roughness of the article may contribute to a reduced dynamic coefficient of friction when compared to the dynamic coefficient of friction of an article that exhibits a lesser degree of surface roughness. For instance, the dynamic coefficient of friction of an article exhibiting surface roughness may be less than the dynamic coefficient of friction of an article that is substantially free of surface roughness.

The surface roughness depth (Rz) may be measured according to DIN 4768 using a profilometer or roughness tester. The average surface roughness depth represents the mean from the individual depths of roughness of five individual lines. For instance, the measurements are made between the highest and lowest points on the surface averaged over five individual lengths.

In one embodiment, the article produced according to the present disclosure may have an average surface area roughness of greater than about 0.1 μm, such as greater than about 0.25 μm, such as greater than about 0.50 μm, such as greater than about 1 μm, such as greater than about 2.5 μm, such as greater than about 5 μm and less than about 30 μm, such as less than about 20 μm, such as less than about 15 μm, such as less than about 10 μm, such as less than about 5 μm, such as less than about 2.5 μm, such as less than about 1 μm.

The present disclosure may be better understood with reference to the following examples.

EXAMPLE

In this example, various polymer compositions were formulated and tested for mechanical properties, including tribological properties.

The polymer composition contained a polyoxymethylene polymer combined with glass fiber, a coupling agent, and an ultra-high molecular weight silicone. In addition, the polymer composition contained other additives which included a nucleating agent, an antioxidant, and a melamine formaldehyde scavenger. The polyoxymethylene polymer included reactive or functional terminal groups. The reactive groups comprised hydroxide groups. Greater than 50% of the terminal groups comprise the hydroxide groups on the polymer. The polyoxymethylene polymer contained terminal hydroxide groups in an amount from about 20 mmol/kg to about 25 mmol/kg. The polyoxymethylene polymer was a copolymer containing 3.4 wt. % dioxolane comonorner and had a MVR of 8 cm³/10 min. The polymer had a melting point of 165° C.

The ultra-high molecular weight silicone was an ultra-high molecular weight polydimethylsiloxane. The ultra-high molecular weight silicone was added to the composition precompounded with a polyoxymethylene polymer. The precompounded composition contained the silicone in an amount of 40% by weight and the polyoxymethylene polymer in an amount of 60% by weight.

The coupling agent used was MDI and the glass fibers included a sizing agent.

The components of each respective composition were mixed together and compounded using a ZSK 25MC (Werner & Pfleiderer, Germany) twin screw extruder (zone temperature 190° C., melt temperature about 210° C.). The screw configuration with kneading elements was chosen so that effective thorough mixing of the components took place. The compositions were extruded and pelletized. The pellets were dried for 8 hours at 120° C. and then injection molded.

The polymer compositions were tested for tensile modulus, stress at break, and notched Charpy. Tensile modulus and stress at break were tested according to ISO Test 527 at a temperature of 23° C. and a test speed of 5 mm/mins using standard ISO test specimens. Notched Charpy impact strength was determined according to ISO Test No. 179-1 at 23° C. Stick-slip tests were also conducted on the polymer compositions to determine the dynamic coefficient of friction and the abrasion or wear in millimeters.

The following polymer compositions were formulated and the following test results were obtained.

Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 POM copolymer (wt. %) 73.89 66.19 66.69 81.19 81.69 UHMW-Si (wt. %) — 3.0 3.0 3.0 3.0 Additives 0.81 0.81 0.81 0.81 0.81 Coupling Agent 0.5 0.5 — 0.5 — Glass Fibers 25 25 25 10 10

Sam- Sam- Sam- Sam- Sam- ple 1 ple 2 ple 3 ple 4 ple 5 Tensile 9200 8600 8300 4700 4800 Modulus Stress at 150 138 123 95 89 Break Notched 12.5 13 8.5 8.8 6.6 Charpy Stick- Dynam- 0.341 0.056 0.081 0.04 0.052 slip ic CoF Abra- 2.11 0 1.04 0 1.07 sion

As shown above, the addition of the ultra-high molecular weight silicone to the polymer composition greatly improved the stick-slip test results. When glass fibers and a coupling agent were present with the ultra-high molecular eight silicone, wear on the polymer sample was non-existent.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part.

Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims. 

1. A polymer composition comprising: a polyoxymethylene polymer, the polyoxymethylene polymer having reactive groups at terminal positions on the polymer; reinforcing fibers present in the polymer composition in an amount from about 5% to about 55% by weight; a coupling agent that couples the polyoxymethylene polymer to the reinforcing fibers; and at least one tribological modifier comprising an ultra-high molecular weight silicone having a kinematic viscosity of greater than about 100,000 mm²S⁻¹.
 2. A polymer composition as defined in claim 1, wherein the ultra-high molecular weight silicone is present in the polymer composition in an amount from about 0.1% to about 10% by weight.
 3. A polymer composition as defined in claim 1, wherein the ultra-high molecular weight silicone is a polydimethylsiloxane.
 4. A polymer composition as defined in claim 1, wherein the composition contains a second tribological modifier.
 5. A polymer composition as defined in claim 4, wherein the second tribological modifier comprises polytetrafluoroethylene.
 6. A polymer composition as defined in claim 4, wherein the second tribological modifier comprises ultra-high molecular weight polyethylene particles.
 7. A polymer composition as defined in claim 1, wherein the composition further comprises calcium carbonate particles, ultrahigh molecular weight polyethylene, stearyl stearate, an aliphatic ester wax composed of a fatty acid and of a monohydric alcohol, a graft copolymer comprising a polyethylene or polypropylene graft base grafted with an acrylonitrile or with a styrene/acrylonitrile copolymer, or a combination thereof.
 8. A polymer composition as defined in claim 1, wherein the reactive groups on the polyoxymethylene polymer comprise hydroxyl groups.
 9. A polymer composition of claim 8, wherein at least 50% of all terminal groups present on the polyoxymethylene polymer comprise hydroxyl groups.
 10. A polymer composition as defined in claim 8, wherein hydroxyl groups are present on the polyoxymethylene polymer in an amount greater than 15 mmol/kg.
 11. A polymer composition as defined in claim 1, wherein the polyoxymethylene polymer has a melt volume flow rate of from 6 cm³/10 min. to about 15 cm³/10 min.
 12. A polymer composition as defined in claim 1, wherein the polyoxymethylene polymer is present in the composition in an amount from about 50% to about 90% by weight, the reinforcing fibers comprising glass fibers and being present in the polymer composition in an amount from about 5% to about 30% by weight, the ultra-high molecular weight silicone being present in the composition in an amount from about 0.5% to about 4% by weight, and the coupling agent being present in the polymer composition in an amount from about 0.1% to about 2% by weight.
 13. A polymer composition as defined in claim 1, wherein the coupling agent comprises an isocyanate.
 14. A polymer composition as defined in claim 1, wherein the coupling agent is present in the composition in an amount from about 0.2% to about 3% by weight.
 15. A polymer composition as defined in claim 1, wherein the reinforcing fibers are coated with a sizing agent, the coupling agent coupling the reactive groups on the polyoxymethylene polymer to the sizing agent.
 16. A polymer composition as defined in claim 1, wherein the composition includes a second polyoxymethylene polymer that is different than the first polyoxymethylene polymer.
 17. A polymer composition as defined in claim 1, wherein the polymer composition exhibits a wear track according to VDA 230-206 of less than 1 mm.
 18. A polymer composition as defined in claim 1, wherein the polymer composition exhibits a dynamic coefficient of friction according to VDA 230-206 of less than about 0.07.
 19. A molded article made from the polymer composition as defined in claim
 1. 20. A polymer article made from the polymer composition as defined in claim 1, the polymer article comprising a gear, a lever, a cam, a roller, a sliding element, a pulley, a latch, a claw, a wiper arm, a conveyor component, a medical inhaler, or a medical injector. 